A method for assembling a magnetic inductor for an electromagnetic pump comprising the following steps: providing a plurality of magnetic laminations having a cross section of an involute of a circle; assembling the plurality of magnetic laminations by fitting same into an inductor core; cutting out at least one housing for an elementary coil; providing and placing an elementary coil inside each housing formed in the cutting step and thereby forming the magnetic inductor. Further, a magnetic inductor formed by implementing such a method and an electromagnetic pump including at least one magnetic inductor.
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1. A method for assembling a magnetic inductor for an electromagnetic pump comprising the following steps:
providing a plurality of identical magnetic plates, each of the magnetic plates extending along a main axis and having a cross section in the shape of an involute of a circle,
assembling the plurality of magnetic plates by interlocking the magnetic plates together in order to form a tubular axial inductor core, the circle of the involute of a circle of the magnetic plates being merged together,
cutting at least one elementary coil footprint in a longitudinal surface of the tubular inductor core selected from an internal longitudinal surface and an external longitudinal surface in order to form at least one housing for an elementary coil,
providing and placing an elementary coil in each housing formed during the cutting step in order to form the magnetic inductor;
wherein between the step of cutting at least one elementary coil footprint and the step of providing and placing an elementary coil, a step of applying an insulating coating on at least part of the surface of the at least one housing formed during cutting, is further provided.
2. The assembly method according to
between the step of providing the plurality of magnetic plates and the assembly step, a step of providing at least one element from a dielectric coating, a friction reduction coating, a dielectric interlayer sheet, a friction reduction interlayer sheet,
wherein during the assembly step said element is disposed so as to be interposed between at least two magnetic plates.
3. The assembly method according to
wherein when providing the at least one element, N copy of said element is provided, one of said N copy of said element being interposed between two consecutive magnetic plates all the M magnetic plates.
4. The assembly method according to
wherein the assembly step includes the following sub-steps:
assembling N subsets of M magnetic plates by interlocking, the circle of the involute of a circle of the M magnetic plates of the same subset being merged together, the remaining O magnetic plates of the M magnetic plates being either distributed in at least part of the N subsets, or assembled in the form of an additional subset of O magnetic plates,
assembling the N subsets and the possible additional subset by interlocking in order to form a tubular inductor core, the circle of the involute of a circle of the magnetic plates being merged together.
5. The assembly method according to
6. The assembly method according to
7. The assembly method according to
wherein during the sub-step of assembling the N subsets by interlocking, the respective copy of the element is disposed so as to be interposed between the corresponding subset and the directly following subset.
8. The method according to
providing at least one element consisting in applying the corresponding coating on at least one of the faces of a magnetic plate.
9. The method according to
providing a cable intended to form said elementary coil,
winding the cable in each of said housings to form the corresponding elementary coil.
10. The method according to
cutting at least one conductor footprint in at least one of the internal longitudinal surface and the external longitudinal surface, said conductor footprint being configured to extend between two elementary coil housings,
after the step of providing and placing an elementary coil in each of the housings and at the step of cutting the at least one conductor footprint, providing a respective conductor for each of the conductor footprints and placing said conductor in the corresponding conductor footprints by connecting the elementary coils housed in the two elementary coil footprints between which the corresponding conductor footprint extends.
11. The method according to
12. A method for manufacturing an electromagnetic pump, including a step of providing a magnetic inductor by means of an assembly method according to
15. A magnetic inductor for an electromagnetic pump being obtained by a method according to
an axial tubular inductor core including a plurality of magnetic plates each of the magnetic plates extending along a main axis and having a cross section in the shape of a involute of a circle, the magnetic plates being assembled by interlocking with the circle of the involute of the circle of the magnetic plates merged together, the magnetic plates being identical with the exception of one or more possible footprint(s), said magnetic plates comprising at least one footprint of an elementary coil cut to form a housing for said elementary coil and which is arranged on a longitudinal surface of the tubular inductor core from an internal longitudinal surface and an external longitudinal surface,
a respective elementary coil in the or each housing formed by cutting the footprint of the tubular inductor core.
16. The magnetic inductor according to
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This is the National Stage of PCT international application PCT/FR2018/052906, filed on Nov. 19, 2018, which claims the priority of French Patent Application No. 1760944, filed Nov. 20, 2017, both of which are incorporated herein by reference in their entirety.
The invention relates to the field of annular electromagnetic pumps and the magnetic inductors which equip them.
Thus, the object of the invention is a method for manufacturing a magnetic inductor, a magnetic inductor and an electromagnetic pump including such a magnetic inductor.
In order to optimise the pumping capacity of annular electromagnetic pumps, it is known to equip them with two magnetic inductors, one internal, delimiting with a protection tube an internal wall of a channel of the electromagnetic pump, the other external, delimiting, with a protection tube an external wall of the channel.
Such an electromagnetic pump 1 thus includes, as illustrated in
For each of the internal and external magnetic inductors 10, 20, the elementary coils 111, 121, 131, 211, 221, 231 follow one another along the central axis 301 of the electromagnetic pump 1. In order to generate a magnetic field sliding along the main axis, the elementary coils 111, 121, 131, 211, 221, 231 of the internal and external magnetic inductors 10, 20 are power supplied by a polyphase current, in
Thus, an electromagnetic pump 1 includes two magnetic inductors 10, 20 each comprising:
Note that in the above and throughout the rest of this document, the terms “inductor core” and “inductor body” are used interchangeably and therefore have the same meaning. It is therefore possible, throughout this text, to substitute “inductor core” by “inductor body” without changing its meaning and teaching.
Currently, the inductor core 100, whether that of the internal magnetic inductor 10 or that of the external magnetic inductor 20, is generally manufactured by means of flat magnetic plates of variable dimensions and disposed axially.
Consequently, during the manufacture of a magnetic inductor 10, 20, said manufacture is made more complex by the need to manage the different sizes of magnetic plates. In addition, the inductor core 100 thus manufactured has a poorly optimised density. Indeed, the arrangement between the different magnetic plates, due to a generally imperfect size/shape adjustment, generates the presence of cavities. It should also be noted that the arrangement and alignment between the different magnetic plates are also made more complex due to the presence in each of the magnetic plates of orifices intended to form the housings of the elementary coils.
In order to partially overcome these problems, it is known from document US 2011/0050376 to use magnetic plates extending along a main axis and having a cross section in the shape of an involute of a circle. With such a shape, it is possible to form the inductor core using magnetic plates having an identical dimensioning while optimising the density of the inductor core.
However, such a manufacturing method has a number of disadvantages. Indeed, in order to provide the notches for housing the elementary coils, it is necessary to drill each of the magnetic plates with orifices before they are shaped into an involute of a circle. However, because of these orifices, the shaping of the involute of a circle is generally imperfect. In addition, during the assembly of the magnetic plates by interlocking, these orifices can interfere with each other and thus cause interlocking difficulties, or even be responsible for the damage to the magnetic plates. Finally, in order to meet the tolerances related to the manufacture of such magnetic inductors, it is necessary to perfectly control both the drilling of these orifices and the alignment of the different magnetic plates. Indeed, the slightest misalignment between the orifices requires a correction of the elementary coil housing that they form. However, such a correction can be detrimental for the electrical insulation.
The invention aims at to least partially overcoming the above disadvantages and thus has the purpose of allowing the manufacture of magnetic inductors having an optimised density with respect to magnetic inductors made from flat magnetic plates, this with a method which does not have the disadvantages of magnetic plate alignments related to the manufacturing method proposed by document US 2011/0053076.
To this end, the invention relates to a method for assembling a magnetic inductor for an electromagnetic pump comprising the following steps:
With the manufacturing method according to the invention, the cutting of the notches being subsequent to the assembly of the magnetic plates and therefore to the alignment of the latter, the risks of misalignment and having to make a correction which would be detrimental to the electrical insulation are completely removed.
In the same way, the orifices forming said notches not yet being formed during the shaping of the magnetic plates and during their assembly to form the inductor core, these two steps are thereby facilitated and not hindered. Thus the manufacturing method according to the invention is therefore simplified with respect to that of document US 2011/0053076 and the risks of damaging the plates greatly limited. Moreover, the inductor thus formed, benefits, in the same way as an inductor described in document US 2011/0053076, from an optimised density related to the use of magnetic plates extending along a main axis and having a cross section in the shape of an involute of a circle.
“Identical magnetic plates” means, in the above and in the rest of this document, that the magnetic plates have an identical shape, within given tolerances.
The method may further comprise, between the step of providing the plurality of magnetic plates and the assembly step, a step of providing at least one element from a dielectric coating, a friction reduction coating, a dielectric interlayer sheet, a friction reduction interlayer sheet,
during the assembly step, said element being disposed so as to be interposed between at least two magnetic plates.
Such elements allow:
During the step of providing magnetic plates, a number N×M magnetic plates can be provided, N being an integer greater than or equal to 1 and M being an integer greater than or equal to 2,
when providing the at least one element, N copy of said element can be provided, a copy of said element being interposed between two consecutive magnetic plates all the M magnetic plates.
In this way, it is possible to obtain a satisfactory effect of said element without necessarily using the same number of elements as magnetic plates.
During the step of providing magnetic plates, a number N×M+O magnetic plates can be provided, N being a natural number greater than or equal to 1 and M being a natural number greater than 2, O being a natural number strictly less than M,
the assembly step including the following sub-steps:
The assembly of the magnetic plates is thereby facilitated.
During the assembly of the N subsets by interlocking in order to form a tubular inductor core, at least two subsets have a misalignment, the subsets can follow one another, preferably misaligned in pairs.
The method may further comprise, between the step of providing the plurality of magnetic plates and the assembly step, a step of providing a respective copy for each subset of the element from a dielectric coating, a friction reduction coating, a dielectric interlayer sheet, a friction reduction interlayer sheet,
during the sub-step of assembling the N subsets by interlocking, the respective copy of the element being disposed so as to be interposed between the corresponding subset and the directly following subset.
With such an element, the insulation and/or assembly of the subsets are optimised.
The element may be at least one from a dielectric coating, a friction reduction coating and wherein each magnetic plate has at least one first and one second face,
the provision of the at least one element consisting in the application of the corresponding coating on at least one of the faces of a magnetic plate.
In this way, the insulation of the magnetic plates and the assembly of the latter are optimised without requiring a step of placing an interlayer sheet.
Between the step of cutting at least one elementary coil footprint and the step of providing and placing an elementary coil, a step of applying an insulating coating on at least part of the surface area of the at least one housing formed during cutting may further be provided.
In this way, good insulation of the inductor core from the elementary coils is ensured.
The step of providing and placing an elementary coil in each housing can comprise the following sub-steps:
During the step of cutting at least one elementary coil footprint, a plurality of footprints can be cut, the method further comprising the following steps:
The magnetic inductor manufactured can be an internal inductor.
Such a method allows forming a magnetic inductor particularly benefiting from the compactness provided by the invention.
The invention also relates to a method for manufacturing an electromagnetic pump including a step of providing a magnetic inductor by means of an assembly method according to the invention.
Such a method allows providing an electromagnetic pump, the inductor of which benefits from the advantages related to the invention.
The invention further relates to a magnetic inductor for an electromagnetic pump capable of being obtained by a method according to the invention, the magnetic inductor including:
Such an inductor has an optimised electrical insulation since during its manufacture there was no need for a correction which would have been detrimental to the electrical insulation.
Said magnetic inductor can be an internal magnetic inductor of the magnetic pump.
Such an inductor particularly benefits from the compactness provided by the method according to the invention.
The invention further relates to an electromagnetic pump including at least one first magnetic inductor according to the invention, the electromagnetic pump preferably including a second magnetic inductor according to the invention.
The present invention will be better understood upon reading the description of exemplary embodiments, given in a purely indicative and non-limiting manner, with reference to the appended drawings wherein:
Identical, similar or equivalent parts of the different figures have the same reference numerals so as to facilitate the passage from one figure to another.
The different parts shown in the figures are not necessarily shown on a uniform scale, to make the figures more readable.
In this case, the magnetic inductor 10 is an internal magnetic inductor of an electromagnetic pump 1.
Such a magnetic inductor 10 includes, in the same way as an internal inductor of the prior art as illustrated in
The inductor core 100 according to the invention has the particularity of including a plurality of identical magnetic plates 103, each of the magnetic plates 103 extending along a main axis AA and having a cross section in the shape of an involute of a circle. Each of these magnetic plates 103 includes orifices, or notches, following each other along the main axis AA. Each of said orifices participates in the formation, with the corresponding orifices of the other magnetic plates 103, of a respective housing 102 for one of the elementary coils 111, 112, 121, 122, 131, 132.
According to a preferred possibility of the invention, the inductor core 10 can include at least one element 107 from a dielectric coating, a friction reduction coating, a dielectric interlayer sheet, a friction reduction interlayer sheet. The element 107 is interposed between two consecutive magnetic plates.
In the above and in the rest of this document, friction reduction coating means a coating of a material having a coefficient of friction with a magnetic plate which is less than the coefficient of friction between two magnetic plates. Such a coating can, for example, be a coating comprising a ceramic material and/or a fluoropolymer such as polytetrafluoroethylenes (PTFE) such as those sold by the company DUPONT under the name Teflon™.
In the same way, a friction reduction interlayer sheet is a sheet whose composition is adapted so that the sheet has a coefficient of friction with a magnetic plate which is less than that between two magnetic plates.
Likewise, a coating or an interlayer sheet can be qualified as dielectric in the case where this coating, or this interlayer sheet, has a relative permittivity greater than or equal to 1.
It will of course be noted that such an element 107 can have two functions, that thus forming, for example, both a dielectric coating and a friction reduction coating or also include two sub-elements, such as a dielectric coating and a friction reduction sheet.
According to a preferred possibility of the invention, the inductor core 100 includes:
Of course, depending on the number of magnetic plates 103 necessary to form the inductor core 100, the number O can perfectly be zero. According to this possibility, the inductor core 100 then includes N×M magnetic plates 103 and N copies of said element 107.
In the same way, according to an advantageous possibility of the invention, M can be equal to 1, O then being zero and the number of copies of the element is then equal to the number of magnetic plates 103.
Thus, for example, such elements may be a ceramic coating applied on a part of the magnetic plates 103, for example all the ten magnetic plates.
It should be noted that, according to a similar possibility, the inductor 10 may also include in each of the housings 102 an electrical insulator, such as a sheet of mica or a coating made of electrically insulating material. Similarly, it is possible within the scope of the invention that one or more, or even all, of the housings are provided with at least one sensor, such as a magnetic field sensor or a thermometer.
Electrical insulator, should be understood here and in the rest of this document, as an interlayer material having a relative permittivity greater than or equal to 1.
Each elementary coil 111, 112, 121, 122, 131, 132 consists of a conductor 110, such as a copper cable, wound in the corresponding housing 102, said conductor 110 including an insulator 109 for electrically insulating each of the turns S of said elementary coil 111, 112, 121, 122, 131, 132 from the turns S which are directly adjacent thereto.
Such an inductor 10 can be manufactured by implementing an assembly method including the following steps:
The step of providing the plurality of magnetic plates 103 may include the following sub-steps:
In the case where a number N×M+O magnetic plates, N being an integer greater than or equal to 1, M being an integer greater than or equal to 2 and O being a natural number strictly less than M, is provided in the step of providing the plurality of magnetic plates 101, the step of assembling the magnetic plates 103 may include the following sub-steps:
According to this same possibility and according to the possibility where N elements 107 are provided each selected from a dielectric coating, a friction reduction coating, a dielectric interlayer sheet, a friction reduction interlayer sheet, the step of assembling the magnetic plates 103 may further include before the step of assembling the N subsets 104 and the possible additional subset 104 by interlocking:
Thus, according to this possibility, a copy of the element 107 is disposed between the first magnetic plate 103 of a first subset and the last magnetic plate 103 of the directly adjacent subset. Such an arrangement can be obtained, for example, by applying a ceramic coating on one of the surfaces of each of the subsets 104, said ceramic coating then acting both as a dielectric coating and as a friction reduction coating.
When assembling the N subsets 104 and the possible additional subset 104, at least one of the subsets may have a misalignment with respect to at least one other subset. In this way, it is possible to limit the appearance of current turns at the ends of the inductor core 100. It can be noted that according to this possibility, the subsets 104 follow one another preferably misaligned in pairs.
It can be noted that according to another possibility of the invention, a copy of the element 107 can be provided between each of the magnetic plates 103. According to this possibility, the assembly step then includes a prior step of providing the set of copies of the element 107.
According to one possibility of the invention, once the inductor core 100 is assembled, the inductor assembly method can comprise the following steps:
This pin, preferably having a length substantially equal to the diameter of the inductor core, allows ensuring the cohesion of the magnetic plates and limiting the risks of misalignment when handling the inductor core 100.
The cutting step can include the following sub-steps:
Once the housings 102 are formed, a step of providing and disposing an electrical insulator 108, such as a sheet of mica, in each of the housings 102 can be provided prior to the step of winding an elementary coil 111, 112, 121, 122, 131, 132 in each housing 102. During this step, a step of placing constraint flanges 402 in order to perfectly maintain the assembly of the magnetic plates 103 and thus maintain the optimised density may also be provided.
The winding step may include, for each of the notches 102, the following steps:
It should be noted that in the context of the example of magnetic inductor 10 illustrated in
Once the elementary coils 111, 112, 121, 122, 131, 132 are placed and in the case where the constraint flanges 402 have been provided to maintain the assembly of the magnetic plates 103, a step of removing the constraint flanges 402 may be provided.
In order to connect the elementary coils 111, 112, 121, 122, 131, 132 to each other, a step of providing and placing conductors 118 to connect the elementary coils 111, 112, 121, 122, 131, 132 to each other can be provided. This placement of conductors 118 can be carried out in accordance with the circuit of winding a magnetic inductor 10 illustrated in
According to this winding circuit, for each of the phases P1, P2, P3 of the polyphase current, the magnetic inductor 10 includes N pairs 1101,2, . . . ,N-1,N, 1201,2, . . . , N-1,N, 1301,2, . . . ,N-1,N of elementary coils 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N, 1211,2, . . . ,N-1,N, 1221,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N, of the same winding direction following one another from the first pair 1101, 1201, 1301 to the Nth pair 110N, 120N, 130N along the magnetic body 100, N being an integer greater than or equal to 2. Each of the pairs 1101,2, . . . ,N-1,N, 1201,2, . . . ,N-1,N, 1301,2, . . . ,N-1,N comprises a first and a second elementary coil 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N, 1211,2, . . . ,N-1,N, 1221,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N which follow one another along the magnetic inductor core 101. Each elementary coil, 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N, 1211,2, . . . ,N-1,N, 1221,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N includes two ends I, O, namely an input type end I and an output type end O.
Of course, in accordance with the operating principle of a coil, the differentiation between the input end I and the output end O is purely artificial. Indeed, the substitution of one by the other is equivalent to a simple reversal of the winding direction of said coil. Thus, the connections which are described above are valid regardless of the choice between the input I and the output O, to the extent that said convention is identical to all the elementary coils 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N, 1211,2, . . . ,N-1,N, 1221,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N of the magnetic inductor 100.
The pairs 1101,2, . . . ,N-1,N, 1201,2, . . . ,N-1,N, 1301,2, . . . ,N-1,N of elementary coils 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N, 1211,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N are distributed along the magnetic inductor core 100 so as to provide a phase alternation P1, P2, P3 and provide a magnetic field sliding along the magnetic inductor core 100.
The connection between the elementary coils 1111,2, . . . ,N-1,N, 1121,2, . . . ,N-1,N 1211,2, . . . ,N-1,N, 1221,2, . . . ,N-1,N, 1311,2, . . . ,N-1,N, 1321,2, . . . ,N-1,N associated with the same phase of the first, the second and the third phase P1, P2, P3 is described below.
Thus, for a given phase P1, P2, P3, the first and the second elementary coil 1111, 1121, 1211, 1221, 1311, 1321 of the first pair 1101, 1201, 1301 are respectively connected to one of the current input and the current output of said phase P1, P2, P3 and to the other of the current input and current output of said phase P1, P2, P3. Thus, as can be seen in
For this same given phase P1, P2, P3, and for each of the first to the N−1st pair 1101,2, . . . ,N-1, 1201,2, . . . ,N-1, 1301,2, . . . ,N-1 associated with said phase P1, P2, P3, the first elementary coil 1111,2, . . . ,N-1, 1211,2, . . . ,N-1, 1311,2, . . . ,N-1 has one of the ends I, O thereof connected to the end of the same type of the first elementary coil 1111,2, . . . ,N-1, which directly follows it along the magnetic inductor core 101. Similarly, for each of the second to Nth pair 1102, . . . ,N-1,N, 1202, . . . ,N-1,N, 1302, . . . ,N-1,N associated with said phase P1, P2, P3, the second elementary coil 1122, . . . ,N-1,N, 1222, . . . ,N-1,N, 1322, . . . ,N-1,N has one of the ends I, O thereof connected to the end of the same type of the second elementary coil 1122, . . . ,N-1,N, 1222, . . . ,N-1,N, 1322, . . . ,N-1,N which directly precedes it.
Thus, as can be seen in
For each of the first to the third phases P1, P2, P3, the first and second elementary coils 111N, 112N, 121N, 122N, 131N, 132N of the Nth pair 110N, 120N, 130N are connected in series. Thus the first elementary coil 111N, 121N, 131N of the last pair 110N, 120N, 130N has its input I connected to the output O of the second elementary coil 112N, 122N, 132N of this same last pair 110N, 120N, 130N.
It will be noted that the connections between the elementary coils are provided, as illustrated in
In the context of such a step of providing and placing the conductor, the assembly method may include, as illustrated in
According to such a possibility of placing the conductors 118 by means of cutting the longitudinal portions of the outer end of some of the magnetic plates 103, for each of the conductors 118, at least one of said conductor 118 and the corresponding space 117 freed by the cutting of the longitudinal portions of the outer end of some of the magnetic plates 103, includes an insulator in order to insulate said conductor from the inductor core 100.
The inductor 10 thus formed, whether it is an internal inductor 10 or an external inductor 20, can then be provided as part of a method for manufacturing an electromagnetic pump 1.
Thus, the method for manufacturing an electromagnetic pump including such a magnetic inductor comprises the following steps:
It can be noted that, alternatively, and according to a possibility illustrated in
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